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Single screw extrusion is one of the most widely used manufacturing processes for thermoplastic processing. The process of screw extrusion of thermoplastics follows a complex relationship with the various processing parameters, the optimum values of which are essential to determine for smooth functioning and maximum throughput. Thermoplastics also exhibit die-swell behavior, which is the free expansion of the material after extrusion. In this research, Taguchi's Method based process optimization is done using L9 (33) orthogonal array arrangement for screw extrusion of thermoplastic ABS (Acrylonitrile Butadiene Styrene). Process parameters such as screw speed, peak temperature, and thermal gradient are simultaneously optimized for high output and dimensional stability by maximizing the specific velocity of extrusion, which is defined as the ratio of extrusion velocity to the extrudate size. It is observed that the screw rotation (RPM) has the most dominant effect, and the processing conditions should be set to achieve the specific velocity above 100 /min for the best results. [ABSTRACT FROM AUTHOR]

Accuracy and complexity on product feature and selection of material for specific application requires matching of manufacturing processes to fulfil the customer requirements with cost effective. Electrochemical machining is a class of NTM (Non-Traditional Machining) widely applicable for machining the precious components like tools and dies. This research is about Machinability Investigation and optimizing Process parameters on electrochemical machining (ECM) for improving the surface quality by reducing the maximum surface peak height in machining of Stainless Steel (12X18H10T). In this investigation the core process parameters like electrode gap, current, voltage and concentration of electrodes were considered as process variables for optimizing maximum profile height on the machined surface. The input variables were varied three levels as minimum, medium and maximum settings. The range of individual process parameters were identified by trail experimentations. The Taguchi L9 experimental design adapted for 3 level 4 factor design to conduct the experimentation and statistical optimization by Taguchi analysis. The optimized parameters were validated by trail experimentation and found acceptable error. The ANOVA used for validate the statistical model identifying theinfluence of process parameters. The optimized values of process parameters suggested and the mathematical model developed to predict the process parameters settings for the required surface quality that is permissible surface profile peak limits. [ABSTRACT FROM AUTHOR]

Electrochemical machining is a class of NTM (Non-Traditional Machining) widely applicable for machining the precious components like tools and dies. The importance of this research is one of the main drawback in NTM is slow process that is Low MRR. This research is about Machinability Investigation and optimizing Process parameters on electrochemical machining (ECM) for improving rate of machining of Stainless Steel (12X18H10T). In this investigation the core process parameters like electrode gap, current, voltage and concentration of electrodes were considered as process variables for optimizing the rate of machining or material removal rate (MRR). The input variables were varied three levels as minimum, medium and maximum settings. The range of individual process parameters were identified by trail experimentations. The Taguchi L9 experimental design adapted for 3 level 4 factor design to conduct the experimentation and statistical optimization by Taguchi analysis. The optimized parameters were validated by trail experimentation and found acceptable error. The ANOVA used for validate the statistical model identifying theinfluence of process parameters. The optimized values of process parameters suggested and the mathematical model developed to predict the process parameters settings for the required MRR. [ABSTRACT FROM AUTHOR]

The unconventional machining processes are popular in machining the difficult to cut type complex contour/ profile. The key parameters are to be machined with care as they directly affects the function and non key dimensions are machined with other than consideration of functional aspect, like design, passage. That means accuracy is less important in those dimensions but finish is to be good. So the machining of engineering materials does not always require optimizing parameters based on multiple responses. This investigation focuses on the sensitiveness of Wire EDM of 12X18H10T - Stainless Steel and identifying the parameters contribution and establish mathematical model to predict values without trial. An austenitic alloy 12X18H10T - Stainless Steel exhibits its inherent mechanical properties even when it expose to extremely high temperature. It has potential application in aerospace engine components manufacturing. This investigation utilized the Taguchi L9 experiential Design with factors of Pulse off Time, Wire Tension, Pulse on Time, and Wire Feed Rate. This study aims to examine Maximize the rate of machining with Taguchi approach in the process of Wire EDM of 12X18H10T - Stainless Steel and establish a mathematical model to predict the highly influencing parameter(s) for desired rate of machining. [ABSTRACT FROM AUTHOR]

Metal Additive Manufacturing (AM) technology allows the manufacture of parts and devices that are geometrically complex, have material elements and can be customized. To take advantage of these skills, it is important to assist designers in exploring untested regions of construction sites. Similarly the current paper provides the concept and method of using the Design for Additive Manufacturing (DFAM) method which includes conceptual design, process selection, latest design stages, and production design. This approach is based on the process-building-material-model behavior typical of building materials. Metal Powder Bed Fusion technology produces solid components, using a hot source to make the interaction between the powdered metal particles one layer at a time. Many Powder Bed Fusion technologies use powder-adding methods as the component is formed, resulting in the final component being added to the metal powder. The main difference in the steel technology Powder Bed Fusion stems from the use of different energy sources. An example CAD system is developed that integrates this approach. Examples of cellular design are used to illustrate the DFAM approach. [ABSTRACT FROM AUTHOR]